Reactor foam sensor systems and methods of use

Abstract

A foam sensor system includes a container bounding a compartment. A foam sensor assembly is mounted on the container and includes: a base being secured to the container; a foam contact being spaced apart from the base and disposed within the compartment of the container, at least a portion of the foam contact having a first diameter; and a transition member extending between the base and the foam contact with at least a portion of the transition member being openly exposed within the compartment of the container, at least a portion of the transition member having a second diameter that is smaller than the first diameter, the foam contact and transition member being connected together so that an electrical signal can pass therethrough.

What is claimed is: 
     
       1. A foam sensor system comprising:
 a container bounding a compartment; and 
 a foam sensor assembly mounted on the container and comprising: 
 a base being secured to the container; 
 a foam contact being spaced apart from the base and disposed within the compartment of the container, at least a portion of the foam contact having a first diameter; and 
 a transition member extending between the base and the foam contact with at least a portion of the transition member being openly exposed within the compartment of the container, at least a portion of the transition member having a second diameter that is smaller than the first diameter, the foam contact and transition member being connected together so that an electrical signal can pass therethrough. 
 
     
     
       2. The foam sensor system as recited in  claim 1 , wherein the second diameter is equal to or less than ⅓ of the size of the first diameter. 
     
     
       3. The foam sensor system as recited in  claim 1 , wherein the first diameter is larger than 3 mm and the second diameter is smaller than 1 mm. 
     
     
       4. The foam sensor system as recited in  claim 1 , wherein the transition member can be bent over an angle of at least 180° without plastic deformation. 
     
     
       5. The foam sensor system as recited in  claim 1 , wherein the transition member is comprised of a nickel-titanium alloy or a copper-aluminum-nickel alloy. 
     
     
       6. The foam sensor system as recited in  claim 1 , wherein the transition member has an exposed length in a range between 2 cm and 15 cm. 
     
     
       7. The foam sensor system as recited in  claim 1 , further comprising a ground assembly mounted on the container and comprising a ground contact disposed within the compartment of the container, the ground assembly being configured so that an electrical potential can be applied between the foam contact and the ground contact. 
     
     
       8. The foam sensor system as recited in  claim 1 , wherein the container comprises a flexible bag comprised of a polymeric material. 
     
     
       9. The foam sensor system as recited in  claim 1 , wherein the foam contact and the transition member are comprised of different materials. 
     
     
       10. The foam sensor system as recited in  claim 1 , wherein the base comprises:
 an elongated body having a first end and an opposing second end; and 
 an annular barb encircling and radially outwardly projecting from the body. 
 
     
     
       11. The foam sensor system as recited in  claim 1 , further comprising an electrical wire coupled to the base. 
     
     
       12. The foam sensor system as recited in  claim 1 , further comprising:
 a housing secured to the container and comprising a stem with a flange radially outwardly projecting therefrom, the stem bounding an opening; and 
 the base being at least partially disposed within the opening of the stem. 
 
     
     
       13. The foam sensor system as recited in  claim 12 , further comprising at least a portion of the transition member being disposed within a portion of the opening of the housing. 
     
     
       14. The foam sensor system as recited in  claim 1 , further comprising:
 a fluid disposed within the compartment of the container and having a top surface; 
 a gas filled gap being formed between the top surface of the fluid and an upper end of the container; 
 a ground contact being in contact with the fluid within the compartment; 
 the foam contact being disposed within the gap within the container so as to be spaced apart from the fluid; and 
 an electrical potential being applied between the foam contact and the ground contact. 
 
     
     
       15. The foam sensor system as recited in  claim 14 , further comprising:
 means for mixing the fluid within the compartment of the container; 
 the fluid comprising a live culture of cells or microorganisms; and 
 a CPU electrically coupled with the foam contact and the ground contact, the CPU being programed to dispense a quantity of an anti-foaming agent into the compartment of the container when an electrical signal passes between the foam contact and the ground contact within the compartment of the container. 
 
     
     
       16. A method for controlling foam, the method comprising:
 sparging a gas into a fluid located within the compartment of the container of the foam sensor system recited in  claim 1 , the sparging gas producing a foam on a top surface of the fluid within a head space at an upper end of the container; 
 applying an electrical potential between the foam contact located within the head space at a location away from the fluid and a ground contact that is at least partially disposed within the fluid; and 
 automatically dispensing an anti-foaming agent into the compartment of the container when the foam produced on the top surface of the fluid touches the foam contact so that an electrical signal is passed between the foam contact and the ground contact. 
 
     
     
       17. The method as recited in  claim 16 , wherein the fluid comprises a live culture of cells or microorganisms. 
     
     
       18. The method as recited in  claim 16 , further comprising sensing the electrical signal and only automatically dispensing the anti-foaming agent when the electrical signal exceeds a predetermined value.